Coated substrates and methods for their preparation

ABSTRACT

Coated substrates containing at least one barrier layer comprising hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm 3  and at least one barrier layer selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national stage filing under 35 U.S.C. §371 of PCT Application No. PCT/US05/028956 filed on 12 Aug. 2005, currently pending, which claims the benefit of U.S. Provisional Patent Application No. 60/602,394 filed 18 Aug. 2004 under 35 U.S.C. §119 (e). PCT Application No. PCT/US05/028956 and U.S. Provisional Patent Application No. 60/602,394 are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to coated substrates and more particularly to coated substrates containing at least one barrier layer comprising hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³ and at least one barrier layer selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.

BACKGROUND OF THE INVENTION

Barrier coatings play an important role in a wide range of applications including electronic packaging, food packaging, and surface treatment by protecting sensitive materials from air, moisture, and other environmental elements. As a result, such coatings increase the reliability and useful lifespan of many consumer products.

Films of hydrogenated silicon oxycarbide suitable for use as interlayer dielectrics or environmental barriers, and methods for producing such films are known in the art. For example, U.S. Pat. No. 6,159,871 to Loboda et al. discloses a chemical vapor deposition method for producing hydrogenated silicon oxycarbide films comprising introducing a reactive gas mixture comprising a methyl-containing silane and an oxygen providing gas into a deposition chamber containing a substrate and inducing a reaction between the methyl-containing silane and oxygen providing gas at a temperature of 25° C. to 500° C.; wherein there is a controlled amount of oxygen present during the reaction to provide a film comprising hydrogen, silicon, carbon and oxygen having a dielectric constant of 3.6 or less on the substrate.

International Application Publication No. WO 02/054484 to Loboda discloses an integrated circuit comprised of a subassembly of solid state devices formed into a substrate made of a semiconducting material, metal wiring connecting the solid state devices, and a diffusion barrier layer formed on at least the metal wiring wherein said diffusion barrier layer is an alloy film having the composition of Si_(w)C_(x)O_(y)H_(z) where w has a value of 10 to 33, x has a value of 1 to 66, y has a value of 1 to 66, z has a value of 0.1 to 60, and w+x+y+z=100 atomic %.

U.S. Pat. No. 6,593,655 to Loboda et al. discloses a semiconductor device having thereon a film produced by introducing a reactive gas mixture comprising a methyl-containing silane and an oxygen providing gas into a deposition chamber containing a semiconductor device and inducing a reaction between the methyl-containing silane and oxygen providing gas at a temperature of 25° C. to 500° C.; wherein there is a controlled amount of oxygen present during the reaction to provide a film comprising hydrogen, silicon, carbon and oxygen having a dielectric constant of 3.6 or less on the semiconductor device.

U.S. Pat. No. 6,667,553 to Cerny et al. discloses a substrate selected from a liquid crystal device, a light emitting diode display device, and an organic light emitting diode display device having thereon a film produced by introducing a reactive gas mixture comprising a methyl-containing silane and an oxygen providing gas into a deposition chamber containing a substrate and inducing a reaction between the methyl-containing silane and oxygen providing gas at a temperature of 25° C. to 500° C.; wherein there is a controlled amount of oxygen present during the reaction to provide a film comprising hydrogen, silicon, carbon and oxygen having a dielectric constant of 3.6 or less on the substrate and to produce a film having a light transmittance of 95% or more for light with a wavelength in the range of 400 nm to 800 nm.

Although the aforementioned references disclose coatings of hydrogenated silicon oxycarbide having good dielectric and barrier properties, there is a need for dielectric coatings having superior resistance to environmental elements, particularly water vapor and oxygen.

SUMMARY OF THE INVENTION

The present invention is directed to a coated substrate, comprising:

a substrate;

a first barrier layer on the substrate, wherein the first barrier layer comprises hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³; and

at least two alternating buffer and barrier layers on the first barrier layer, wherein each alternating buffer layer comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³, and each alternating barrier layer is independently selected from hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, provided at least one alternating barrier layer is selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.

The present invention is also directed to a coated substrate, comprising:

a substrate;

a first buffer layer on the substrate, wherein the first buffer layer comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³; and

at least three alternating barrier and buffer layers on the first buffer layer, wherein each alternating barrier layer is independently selected from hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, and each alternating buffer layer comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³, provided at least one alternating barrier layer is hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, and at least one alternating barrier layer is selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.

The barrier layers of the coated substrate have a low water vapor transmission rate, typically from 10⁻¹ to 10⁻³ g/m²/day. Also, the barrier layers have low permeability to oxygen and metal ions, such as copper and aluminum. Moreover, the barrier layers have high resistance to cracking and low compressive stress. Further, the barrier layers comprising hydrogenated silicon oxcycarbide have higher density and lower porosity than conventional silicon oxycarbide films.

The methods of the present invention can be carried out using conventional equipment and techniques. For example, the hydrogenated silicon oxycarbide of the buffer and barrier layers can deposited using chemical vapor deposition and dual frequency chemical vapor deposition, respectively. Moreover, barrier layers of aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, can be deposited using conventional physical vapor deposition techniques, such as evaporation (thermal and electron beam), RF sputtering, and DC magnetron sputtering.

The barrier layer of the present invention can be used as an interlayer dielectric and/or a barrier against moisture and oxygen in numerous devices, including semiconductor devices, liquid crystals, light-emitting diodes, organic light-emitting diodes, optoelectronic devices, optical devices, photovoltaic cells, thin film batteries, and solar cells.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional view of a first embodiment of a coated substrate according the present invention.

FIG. 2 shows a cross-sectional view of a second embodiment of a coated substrate according the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIG. 1, a first embodiment of a coated substrate according to the present invention comprises a substrate 100; a first barrier layer 102 on the substrate 100, wherein the first barrier layer 102 comprises hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³; and at least two (four shown) alternating buffer 104 and barrier 106 layers on the first barrier layer 102, wherein each alternating buffer layer 104 comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³, and each alternating barrier layer 106 is independently selected from hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, provided at least one alternating barrier layer 106 is selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride. The first embodiment of the coated substrate typically comprises from 2 to 16, alternatively from 4 to 10 alternating buffer and barrier layers on the first barrier layer.

The substrate can be a rigid or flexible material having a planar, complex, or irregular contour. Also, the substrate can be transparent or nontransparent to light in the visible region (˜400 to ˜700 nm) of the electromagnetic spectrum. As used herein, the term “transparent” means the substrate has a percent transmittance of at least 30%, alternatively at least 60%, alternatively at least 80%, for light in the visible region of the electromagnetic spectrum. Further, the term “nontransparent” means the substrate has a percent transmittance less than 30% for light in the visible region of the electromagnetic spectrum.

Examples of substrates include, but are not limited to, semiconductor materials such as silicon, silicon having a surface layer of silicon dioxide, and gallium arsenide; quartz; fused quartz; aluminum oxide; ceramics; glass; metal foils; polyolefins such as polyethylene, polypropylene, polystyrene, polyethylene terephthalate (PET), and polyethylene naphthalate; fluorocarbon polymers such as polytetrafluoroethylene and polyvinylfluoride; polyamides such as Nylon; polyimides; polyesters such as poly(methyl methacrylate); epoxy resins; polyethers; polycarbonates; polysulfones; and polyether sulfones. The substrate can be a single material or a composite comprising two or more different materials.

The first barrier layer comprises hydrogenated silicon oxycarbide typically having a density of at least 1.6 g/cm³, alternatively at least 1.7 g/cm³, alternatively at least 1.8 g/cm³, at 25° C. Typically, the hydrogenated silicon oxycarbide of the barrier layer has a density of from 1.7 to 2.5 g/cm³, alternatively from 1.7 to 2.0 g/cm³, alternatively from 1.8 to 2.0 g/cm³, at 25° C. The density of the hydrogenated silicon oxycarbide can be readily determined by measuring the mass, thickness, and surface area of the deposit.

The hydrogenated silicon oxycarbide of the first barrier layer contains silicon, oxygen, carbon, and hydrogen. For example, the hydrogenated silicon oxycarbide may be represented by the formula Si_(m)O_(n)C_(p)H_(q) wherein m has value of from 10 to 33 atomic %, alternatively from 18 to 25 atomic %; n has a value of from 1 to 66 atomic %, alternatively from 10 to 20 atomic %; p has a value of from 1 to 66 atomic %, alternatively from 15 to 38 atomic %; q has a value of from 0.1 to 60 atomic %, alternatively from 25 to 40 atomic %; and m+n+p+q=100 atomic %.

The first barrier layer typically has a thickness of from 0.2 to 10 μm, alternatively from 0.2 to 5 μm, alternatively from 0.2 to 2 μm. When the thickness of the first barrier layer is less than 0.2 μm, the water vapor transmission rate of the layer typically increases. When the thickness of the first barrier layer is greater than 10 μm, the layer may be susceptible to cracking.

The first barrier layer typically has a percent transmittance of at least 30%, alternatively at least 50%, alternatively at least 70%, for light in the visible region (˜400 to ˜700 nm) of the electromagnetic spectrum. For example a barrier layer having a thickness of 1 μm on a polyethylene terephthalate substrate having a thickness of 150 μm is typically at least 70%.

The first barrier layer can be deposited by introducing a reactive gas mixture comprising a silicon-containing compound, argon, and oxygen into a deposition chamber containing a substrate, wherein the silicon-containing compound is selected from at least one silane, at least one siloxane, and a mixture thereof, the ratio of the flow rate of the argon to the flow rate of the silicon-containing compound is from 10 to 30, the ratio of the flow rate of the oxygen to the flow rate of the silicon-containing compound is from 0.15 to 1.0, the substrate temperature is from 20 to 80° C., and the pressure is from 1.33 to 60 Pa; applying an RF power to the gas mixture to generate a plasma, wherein the RF power is from 300 to 1000 W; and applying an LF power to the substrate, wherein the LF power is from 50 to 120 W, to deposit a first barrier layer comprising hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³ on the substrate.

In the first step of the method, a reactive gas mixture comprising a silicon-containing compound, argon, and oxygen is introduced into a deposition chamber containing a substrate, wherein the silicon-containing compound is selected from at least one silane, at least one siloxane, and a mixture thereof, the ratio of the flow rate of the argon to the flow rate of the silicon-containing compound is from 10 to 30, the ratio of the flow rate of the oxygen to the flow rate of the silicon-containing compound is from 0.15 to 1.0, the substrate temperature is from 20 to 80° C., and the pressure is from 1.33 to 60 Pa.

The silicon-containing compound of the reactive gas mixture is selected from at least one silane, at least one siloxane, and a mixture thereof. Examples of silanes include, but are not limited to, methyl-containing silanes, such as methylsilane, dimethylsilane, trimethylsilane, and tetramethylsilane; and alkoxysilanes, such as dimethoxydimethylsilane, trimethoxymethylsilane, tetramethoxysilane, triethoxymethylsilane, diethoxydimethylsilane, triethoxymethylsilane, triethoxyvinylsilane, tetraethoxysilane, dimethoxymethylphenylsilane, trimethoxyphenylsilane, 3-glycidoxypropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, diethoxymethylphenylsilane, tris(2-methoxyethoxy)vinylsilane, triethoxyphenylsilane, and dimethoxydiphenylsilane. Examples of siloxanes include, but are not limited to, tetramethyldisiloxane, hexamethyldisiloxane, and tetraethoxysilane. The silicon-containing compound can be a single silane, a mixture of two or more different silanes, a single siloxane, a mixture of two or more different siloxanes, or a mixture of at least one silane and at least one siloxane.

The method of the present invention can be carried out using a conventional parallel plate chemical vapor deposition system operating in a dual frequency mode. In such systems, the deposition chamber contains a top electrode, typically the shower head, connected to a radiofrequency (RF) power source and a bottom electrode, typically the substrate holder, connected to a low frequency (LF) power source. The RF power source typically provides a power of from 10 to 1000 W at a frequency of from 1 to 20 MHz. An RF frequency of 13.56 MHz is generally employed in CVD systems. The LF power source typically provides a power of from 10 to 1200 W at a frequency of from 325 to 375 KHz. Also, filtering is typically employed to minimize the interaction between the two signals. For example an inductor and a capacitor are typically used to ground the top and the bottom electrodes, respectively.

The flow rate of the silicon-containing compound is typically from 20 to 150 sccm (standard cubic centimeters per minute), alternatively from 30 to 120 sccm, alternatively from 30 to 80 sccm.

The flow rate of the argon is typically from 200 to 1500 sccm, alternatively from 300 to 1200 sccm, alternatively from 300 to 800 sccm.

The flow rate of the oxygen is typically from 5 to 100 sccm, alternatively from 5 to 60 sccm, alternatively from 5 to 40 sccm.

The ratio of the flow rate of the argon to the flow rate of the silicon-containing compound is typically from 10 to 30, alternatively from 10 to 20, alternatively from 10 to 15. When the ratio of the flow rate of the argon to the flow rate of the silicon-containing compound is greater than 30 sccm, a substantial increase in substrate temperature may occur.

The ratio of the flow rate of the oxygen to the flow rate of the silicon-containing compound is typically from 0.15 to 1.0, alternatively from 0.5 to 1.0, alternatively from 0.5 to 0.8. When the ratio of the flow rate of the oxygen to the flow rate of the silicon-containing compound is less than 0.15, the barrier layer may largely comprise silicon carbide. When the ratio of the flow rate of the oxygen to the flow rate of the silicon-containing compound is greater than 1.0, the water vapor transmission rate of the layer typically increases.

The substrate temperature is typically from 20 to 80° C., alternatively from 25 to 50° C., alternatively from 25 to 40° C.

The deposition pressure is typically from 1.33 to 60 Pa, alternatively from 1.33 to 25 Pa, alternatively from 1.33 to 15 Pa. When the pressure is greater than 60 Pa, the water vapor transmission rate of the layer typically increases.

In the second step of the method, an RF power is applied to the gas mixture to generate a plasma, wherein the RF power is from 300 to 1000 W. Alternatively, the RF power is from 400 to 800 W or from 400 to 600 W.

In the third step of the method, an LF power is applied to the substrate, wherein the LF power is from 50 to 120 W, to produce a first barrier layer having a density of at least 1.6 g/cm³ on the substrate. Alternatively, the LF power is from 60 to 100 W or from 65 to 85 W.

Each alternating buffer layer comprises hydrogenated silicon oxycarbide typically having a density less than 1.6 g/cm³, alternatively less than 1.4 g/cm³, at 25° C. Typically, the hydrogenated silicon oxycarbide of the alternating buffer layer has a density of from 1.0 to 1.5 g/cm³, alternatively from 1.1 to 1.5 g/cm³, alternatively from 1.2 to 1.5 g/cm³, at 25° C. The density of the hydrogenated silicon oxycarbide can be readily determined by measuring the mass, thickness, and surface area of the deposit.

In addition to its barrier properties, the alternating buffer layer provides a smooth surface upon which the alternating barrier layer can be deposited. Also, the alternating buffer layer reduces the compressive stress of the coated substrate.

The hydrogenated silicon oxycarbide of the alternating buffer layer contains silicon, oxygen, carbon, and hydrogen and may be represented by the formula given above for the hydrogenated silicon oxycarbide of the first barrier layer.

The alternating buffer layer typically has a thickness of from 0.2 to 10 μm, alternatively from 0.2 to 5 μm, alternatively from 0.2 to 2 μm. When the thickness of the alternating buffer layer is less than 0.2 μm, the buffer layer may not provide adequate coverage of the underlying barrier layer. When the thickness of the alternating buffer layer is greater than 10 μm, the layer may be susceptible to cracking.

The alternating buffer layer typically has a percent transmittance of at least 60%, alternatively at least 70%, alternatively at least 80%, for light in the visible region (˜400 to ˜700 nm) of the electromagnetic spectrum. For example a buffer layer having a thickness of 1 μm on a polyethylene terephthalate substrate having a thickness of 150 μm is typically at least 80%.

Methods of depositing the alternating buffer layer of hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³ are well known in the art, as exemplified in U.S. Pat. No. 6,159,871 to Loboda et al.; WO 02/054484 A2 to Loboda; U.S. Pat. No. 5,718,967 to Hu et al.; and U.S. Pat. No. 5,378,510 to Thomas et al. For example, hydrogenated silicon oxycarbide films having a density up to about 1.4 g/cm³ can be deposited by chemical vapor deposition as described in U.S. Pat. No. 6,159,871. Briefly, this method involves introducing a reactive gas mixture comprising a methyl-containing silane and an oxygen-providing gas into a deposition chamber containing a substrate and inducing a reaction between the methyl-containing silane and the oxygen-providing gas at a temperature of 25 to 500° C.; wherein there is a controlled amount of oxygen present during the reaction to provide a film comprising hydrogen, silicon, carbon, and oxygen having a dielectric constant of 3.6 or less on the substrate. Examples of methyl-containing silanes include methyl silane, dimethylsilane, trimethylsilane, and tetramethylsilane. Examples of oxygen-providing gases include, but are not limited to, air, ozone, oxygen, nitrous oxide, and nitric oxide.

The amount of oxygen present during the deposition process can be controlled by selection of the type and/or amount of the oxygen-providing gas. The concentration of oxygen-providing gas is typically less than 5 parts per volume, alternatively from 0.1 to 4.5 parts per volume, per 1 part per volume of the methyl-containing silane. When the concentration of oxygen is too high, the process forms a silicon oxide film with a stoichiometry close to SiO₂. When the concentration of oxygen is too low, the process forms a silicon carbide film with a stoichiometry close to SiC. The optimum concentration of the oxygen-containing gas for a particular application can be readily determined by routine experimentation.

Hydrogenated silicon oxycarbide films having a density between 1.4 and 1.6 g/cm³ can be prepared by introducing a reactive gas mixture comprising a silicon-containing compound, argon, and oxygen into a deposition chamber containing the substrate having the barrier layer, wherein the silicon-containing compound is selected from at least one silane, at least one siloxane, and a mixture thereof, the ratio of the flow rate of the argon to the flow rate of the silicon-containing compound is from 1 to 10, the ratio of the flow rate of the oxygen to the flow rate of the silicon-containing compound is from 0.5 to 2.0, the substrate temperature is from 25 to 50° C., and the pressure is from 5 to 40 Pa; applying an RF power to the gas mixture to generate a plasma, wherein the RF power is from 150 to 300 W; and applying an LF power to the substrate, wherein the LF power is from 15 to 30 W.

Each alternating barrier layer is independently selected from hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, provided at least one alternating barrier layer is selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride. As used herein, the term “alternating barrier layer” refers to a single layer of hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³; a single layer of aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, or titanium oxynitride; or two or more different layers, each selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.

The alternating barrier layer typically has a thickness of from 0.2 to 10 μm, alternatively from 0.2 to 5 μm, alternatively from 0.2 to 2 μm. When the thickness of the alternating barrier layer is less than 0.2 μm, the water vapor transmission rate of the layer typically increases. When the thickness of the alternating barrier layer is greater than 10 μm, the layer may be susceptible to cracking.

The alternating barrier layer of hydrogenated silicon oxycarbide and methods of depositing it are as described above for the first barrier layer. The individual layers of aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride typically have a thickness of from 0.2 to 3 μm, alternatively from 0.2 to 2 μm alternatively from 0.2 to 1 μm. Barrier layers of these metals, alloys, and oxides can be deposited using conventional methods, such as thermal evaporation, co-evaporation, RF sputtering, and DC magnetron sputtering.

As shown in FIG. 2, a second embodiment of a coated substrate according to the present invention comprises a substrate 200; a first buffer layer 202 on the substrate 200, wherein the first buffer layer 202 comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³; and at least three (four shown) alternating barrier 204 and buffer 206 layers on the first buffer layer 202, wherein each alternating barrier layer 204 is independently selected from hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, and each alternating buffer layer 206 comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³, provided at least one alternating barrier layer 204 is hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, and at least one alternating barrier layer 204 is selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.

The second embodiment of the coated substrate typically comprises from 3 to 10, alternatively from 3 to 5 alternating barrier and buffer layers on the first buffer layer. In addition to their barrier properties, the first buffer layer and the alternating buffer layer(s) provide a smooth surface upon which the alternating barrier layers can be deposited. Also, the first buffer layer and the alternating buffer layer(s) reduce the compressive stress of the coated substrate.

Each alternating barrier layer and each alternating buffer layer are as described above for the first embodiment of the coated substrate. Also, the first buffer layer is as described above for the alternating buffer layer of the first embodiment. Moreover, the barrier and buffer layers of the second embodiment can be deposited using the methods described above for the first embodiment.

The barrier layers of the coated substrate have a low water vapor transmission rate, typically from 10⁻¹ to 10⁻³ g/m²/day. Also, the barrier layers have low permeability to oxygen and metal ions, such as copper and aluminum. Moreover, the barrier layers have high resistance to cracking and low compressive stress. Further, the barrier layers comprising hydrogenated silicon oxycarbide have higher density and lower porosity than conventional silicon oxycarbide films.

The methods of the present invention can be carried out using conventional equipment and techniques. For example, the hydrogenated silicon oxycarbide of the buffer and barrier layers can deposited using chemical vapor deposition and dual frequency chemical vapor deposition, respectively. Moreover, barrier layers of aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, can be deposited using conventional physical vapor deposition techniques, such as thermal evaporation, RF sputtering, and DC magnetron sputtering.

The barrier layer of the present invention can be used as an interlayer dielectric and/or a barrier against moisture and oxygen in numerous devices, including semiconductor devices, liquid crystals, light-emitting diodes, organic light-emitting diodes, optoelectronic devices, optical devices, photovoltaic cells, thin film batteries, and solar cells.

EXAMPLES

The following examples are presented to better illustrate the coated substrates and methods of the present invention, but are not to be considered as limiting the invention, which is delineated in the appended claims.

The buffer and barrier layers comprising hydrogenated silicon oxycarbide in the Examples were deposited using a Model No. 2212 HDP parallel plate chemical vapor deposition system from Applied Process Technologies (Tucson, Ariz.) operating in a dual frequency mode at a substrate temperature of 25° C., a pressure of 0.09 Torr (12.0 Pa), an RF power source connected to the top electrode (shower head) and an LF power source connected to the bottom electrode (substrate holder).

The deposition chamber was thoroughly cleaned before the preparation of each coated substrate by first plasma etching the interior surfaces of the chamber for 5 to 10 min. using a plasma generated from CF₄ and O₂ at a pressure of 40 Pa, a CF₄ flow rate of 500 sccm, an O₂ flow rate of 100 sccm, an LF power of 40 W, and an RF power of 500 W. After plasma etching, the walls of the chamber were wiped with isopropyl alcohol.

The barrier layers comprising titanium, aluminum, and titanium nitride in the examples were deposited at a rate of about 0.02-0.05 μm/min. by DC magnetron sputtering.

The polyethylene terephthalate (PET) substrates in the Examples (coated and uncoated) were treated with an argon plasma for 30 s at a pressure of 12.0 Pa, an argon flow rate of 500 sccm, an LF power of 40 W, and an RF power of 300 W.

Water vapor transmission rates (WVTR) of coated and uncoated PET substrates were determined using a MOCON PERMATRAN-W Permeation Test System at a temperature of 37.8° C. and a relative humidity of 90%. Coated PET test specimens were clamped into the diffusion cell, which was then purged with moisture-free nitrogen (10 sccm) until a stable water vapor transmission rate was established.

Compressive stress of coated PET substrates was determined using a Tencor FLX-2320 (KLA Tencor, Milpitas, Calif.) Thin Film Stress Measurement System in an atmosphere of nitrogen at temperature of 18-22° C.

Density of buffer and barrier layers comprising hydrogenated silicon oxycarbide was determined by measuring the mass, thickness, and surface area of a film deposited on a circular substrate having a diameter of 10.2 cm. The mass of a layer was determined using an analytical balance having an accuracy of 1×10⁻⁵ g under ambient conditions (25° C., 101.3 kPa).

Film thickness and refractive index were been determined using a Spectroscopic Ellipsometer (J. A. Woollam Co., Inc., Lincoln, Nebr.) operating under ambient conditions. Test specimens were prepared by deposing films on p-Si wafers having a diameter of 10.2 cm and resistivity greater than 5 ohm·cm.

Examples 1-3

In each of Examples 1 and 2, coated substrates having the following multilayer structures were prepared using the process conditions shown in Table 1:

Example 1

PET/Buffer/Barrier A/Buffer/Barrier A/Buffer/Barrier B/Buffer

Example 2

PET/Buffer/Barrier A/Buffer/Barrier A/Buffer/Barrier C/Buffer

where PET refers to a circular sheet of plasma-treated polyethylene terephthalate (see above) having a diameter of 20 cm and a thickness of 175 μm, Buffer refers to a buffer layer of hydrogenated silicon oxycarbide having a density of 1.5 g/μm³; Barrier A refers to a barrier layer of hydrogenated silicon oxycarbide having a density of 1.9 g/cm³; Barrier B refers to a barrier layer consisting of a layer of titanium (˜300 nm) on the underlying buffer layer and a layer of aluminum (˜300 μm) on the layer of titanium; and Barrier C refers to a barrier layer consisting of a layer of titanium nitride (˜300 nm) on the underlying buffer layer and a layer of aluminum (˜300 m) on the layer of titanium nitride. In Example 3, the water vapor transmission rate (WVTR) of an uncoated plasma-treated substrate having a diameter of 10 cm and a thickness of 175 μm was measured for comparison with the coated substrates of Examples 1 and 2. The properties of the buffer and barrier layers of the coated substrates are shown in Table 1 and the properties of the uncoated and coated substrates are shown in Table 2.

TABLE 1 Process Parameters Gas Flow Rate, Power, Film Properties Type of sccm W DR, T, Stress, d, Ex. Layer TMS Ar O₂ LF RF nm/min. nm RI MPa g/cm³ 1 buffer 30 180 25 20 280 200 450 1.5 40 1.5 barrier 40 800 20 85 600 225 450 1.87 415 1.9 2 buffer 30 180 25 20 280 200 520 1.5 40 1.5 barrier 40 800 20 85 650 250 500 1.87 415 1.9 TMS is trimethylsilane, LF is low frequency, RF is radiofrequency, DR is deposition rate, T is average thickness, RI is refractive index, Stress refers to compressive stress, and d is density.

TABLE 2 Properties of Coated Substrate WVTR Coating Thickness Example g/m²/day μm 1 <1 × 10⁻³ 3.3 2 0.04 3.6 3 3.2  uncoated WVTR is water vapor transmission rate, Coating Thickness refers to the total thickness of the buffer and barrier layers combined, and uncoated refers to an uncoated PET substrate. 

1. A coated substrate, consisting of: a substrate; a first barrier layer on the substrate, wherein the first barrier layer comprises hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³; and at least two alternating buffer and barrier layers on the first barrier layer, wherein each alternating buffer layer comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³, and each alternating barrier layer is independently selected from hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, provided at least one alternating barrier layer is selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.
 2. The coated substrate according to claim 1, wherein the coated substrate comprises from 2 to 16 alternating buffer and barrier layers on the first barrier layer.
 3. The coated substrate according to claim 1, wherein the hydrogenated silicon oxycarbide of the first barrier layer and the alternating barrier layers has a density of from 1.7 to 2.5 g/cm³.
 4. The coated substrate according to claim 1, wherein the first barrier layer and the alternating buffer and barrier layers each have a thickness of from 0.2 to 10 μm.
 5. The coated substrate according to claim 1, wherein the hydrogenated silicon oxycarbide of the alternating buffer layers has a density of from 1.0 to 1.5 g/cm³.
 6. A coated substrate, consisting of: a substrate; a first buffer layer on the substrate, wherein the first buffer layer comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³; and at least three alternating barrier and buffer layers on the first buffer layer, wherein each alternating barrier layer is independently selected from hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride, and each alternating buffer layer comprises hydrogenated silicon oxycarbide having a density less than 1.6 g/cm³, provided at least one alternating barrier layer is hydrogenated silicon oxycarbide having a density of at least 1.6 g/cm³, and at least one alternating barrier layer is selected from aluminum, aluminum oxide, aluminum nitride, aluminum oxynitride, titanium, titanium oxide, titanium nitride, and titanium oxynitride.
 7. The coated substrate according to claim 6, wherein the coated substrate comprises from 3 to 10 alternating barrier and buffer layers on the first buffer layer.
 8. The coated substrate according to claim 6, wherein the hydrogenated silicon oxycarbide of the first buffer layer and the alternating buffer layers has a density of from 1.0 to 1.5 g/cm³.
 9. The coated substrate according to claim 6, wherein the first buffer layer and the alternating barrier and buffer layers each have a thickness of from 0.2 to 10 μm.
 10. The coated substrate according to claim 6, wherein the hydrogenated silicon oxycarbide of the alternating barrier layers has a density of from 1.7 to 2.5 g/cm³. 